ML20196G947

Forwards Summary of 880609 Meeting in Region II Ofc Re Emergency Diesel Generator Reliability Concerns.List of Attendees,Brief Meeting Summary & Util Handout Also Enlc

ML20196G947
Person / Time
Site:	Catawba
Issue date:	06/20/1988
From:	Reyes L NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
To:	Tucker H DUKE POWER CO.
References
NUDOCS 8807060059
Download: ML20196G947 (37)

Text

. , . .- - _ - - _ - - _ - - - - - - _ _ _ - .

A ,

JilN 2 01988

' Docket:Nos. 50-413, 50-414-License Nos. NPF-35,.NPF-52

. Dyke Power Company W TN: Mr.- H. : B. Tucker, Vice Pretident

. Nuclear Production Department 422 South Chu.ch Street

-Charlotte,'NC 28242 Gentlemen:

SUBJECT:

MEETING

SUMMARY

- CATAWBA - DOCKET NOS. 50-413 AND 50-414 This letter refers to the. meeting conducted at your request in the NRC Region II~ office on June 9,1988. This was a . technical meeting to discuss emergency diese1 ~ generator reliability concerns at Catawba. A-list of attendees, a brief summary anti a copy of your handout are enclosed.

It is our opinion that this neeting was beneficial, and provided for a better-understanding of diesel ' generator problems and your corrective actions at

-Catawba.

In accordance with Section 2.790 of the NRC's "Rules of Practice," Part 2, Title 10, Cnde of Federal Regulations, a copy of this letter and its enclosures will be placed in the NRC Public Document Room.

Should you have any questions concerning this matter, we will be pleased to discuss them.

Sincerely, d , t.xa. M i

- 4f Luis A. Reyes, Director

Enclosures:

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1. _ Meeting Summary 2.. . Meeting Attendees

3. Duke Power Company Handout w/encls:

. B. Owen, Station Manager Senior Resident Inspector - McG: ire bec w/er is: (See page 2) 8807060059 880620 PDR II P

ADOCK 05000413 PDC y;gy r-

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Duke Power Company 2 JUN 2 0 b88 b c w/encis:

N. Jabbcur, NRR c C Resid'nt Inspector DRS, Technical Assistant Document Control Desk State of Soutt Carolina l

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. ENCLOSURE 2

. MEETING ATTENDEES Duke Power Company c T. B. 0 wen, Manager, Catawbc Nuclear Station (CNS)

X M. R. McElwee, Maintenance, CNS

.S~. Lindsey, Maintenance, CNS P. LeRoy, Licensing, General Office

'R.-M. G1over, Compliance Engineer,.CNS-W. Green, IAE, CNS '

R. Casler, Operations, CNS .

G. Smith, Maintenance Superintendent, CNS

~ Nuclear Regulatory Commission 4 A'.- F. Gibson,. Director, Division of Reactor Safety (DRS)

[- .V. L. Brownlee; Chief, Division of Reactor Projects Branch 3 (CRP)

T. A. Peebles, Chief,. Reactor Projects Section 3f., DRP D. B. Matthews, Director, Project Directorate 2-3, NRR K. N. Jabbour, Project Manager,-NRR l M. S. Lesser', Resident inspector, Catawba B. R. Bonser, Project Engineer, Reactor Projects Section 3A, DDP F. Jape .Section Chief, DRS

0. Tondi~, NRR.

T. E. Corlon, Section Chief, DRS A. Szczepaniec, Reactor Inspector, DRS e

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s ENCLOSURE-1 MEETING

SUMMARY

- On Mune'9, 1988 repres'entatives of Duke Power Company.(DPC) met with the NRC in' the Region 11' office in Atlanta, Genrgia to discuss recent emergency diesel-generatorJ(D/G) reliability problems at' Catawba. A list.'of meeting attendees is in_ Enclosure ~2.

CPC gave a' presentation which addressed NRC concerns reg'arding a recent increase in D/G failures. The recent D/G failures appear to have been c.aused~

'by an -= inappropriately constructed pressure sensor in 'the pneumatic control system and poor airiquality. DPC covered their investigation of the current problems, past D/G. problems and' program enhancements and modifications which should improve.0/G reliability.

An outline of DPC's presentation is given in Enclosure 3.

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f' ENCLOSURE 2 MEETING ATTENCEES Duke Power Company T. B. Owen, Manager, Catawba Nuclear Station (CNS)

M. R. McElwee, Maintenance, CNS S. Lindsey, Maintenance, CNS P. LeRoy, Licensing, General Office R. M. Glover, Compliance Engineer, CNS W. Green, IAE, CNS R. Casler, Operations, CNS G. Smith, Maintenance Superintendent, CNS Nuclear Regulatory Commisslon A. F. Gibson, Director, Division of Reactor Safety (DRS)

V. L. Brownlee, Chief, Division of Reactor Projects Branch 3 (DRP)

T. A. Peebles, Chief, Reactor Projects Section 3A, DRP D. B. Matthews, Director, Project Directorate 2-3, NRR K. N. Jabbour, Project Manager, NRR M. S. Lesser, Resident inspector, Catawba B. R. Bonser, Project Engineer, Reactor Projects Section 3A, DRP F. Jape, Section Chief, DRS D. Tondi, NRR T. E. Conlon, Section Chief, DRS A. Szczepaniec, Reactor Inspector, DRS t

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l O. GENERAL INFORMATO0N ON PNEUHATIC CONTROL SYSTEM l i

A.8YSTEM OPERATION.

B.8EN80R OPERATION.

10.

SUMMARY

OF RECENT TROPS.

100.CORROSDON PROBLEMS AND MANUFACTURONG FLAWS OV. RESOLUTOONS.

V.PAST PROBLEMS.

! VI. PROGRAM ENHANCEMENTS AND MODOFOCATIONS.

VOI. ADDITIONAL PROGRAM ENHANCEMENTS.

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SUMMARY

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-i TRIP HI TEMP JACKET WATER '

TRIP HI VIBRATION -

• TRIP LO PRESS TURBO OIL (2)

• TRIP LO PRESS LUBE OIL (1)

TRIP HI PRESS CRAliKCASE NON EMERGENCY TRIPS

• TRIP LO LO PRESS LUBE OIL (3) EMEICENCY TRIP VIBRATION LOCKOUT ) 60sec P2 a switch I I OR '

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RECHNT D:ESHL GERIMATOR FA LURES D&TE D/G DESCR0P700M 3-22-88 1A D/G TRIPPED AFTER-80 SECONDS.hAE DISCOVERED A SLIGHT NICK ON THE DIAPHRAGM 0F LOGIC ELEMENT "0R8"."0R8" WAS REPLACED AND AIR FOLTER WAS CLEANED.MO OTHER ABNORMALITIES SEEN.

4-12-88 1A D/G TRIPPED AFTER-80 SECONDS.THE 3 LLLO SENSORS WERE FOUND TO HAVE INTERNAL CORROSION.ONE WAS FAILING PERIODOCALLY WHEN TESTED.THE OTHER TWO APPEARED 70 SE WORKING PROPERLY DESPITE THE CORROSION. ALL 3 SEN80R0 WERE REPLACED.

4-12-88 2B D/G TRIPPED AFTER-77 SECONDS.

2/3 LLLO SENSORS WERE FOUND TO BE VENTONG CONTONUOUSLY. ALL THREE MAD SIGNS OF INTERNAL CORROSION.EACH WAS REPLACED.

4=19-88 1A D/G TRIPPED AFTER-80 SECONDS.NO EXACT CAUSE COULD BE FOUND. ALL SENSORS THAT COULD HAVE CAUSED THE TRIP WERE REPLACED.

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4,e RECENT D{H82L GENERATOR FA: LURES DATE D/G DEscRaPTacN 4-28-88 1A D/G TRIPPED AFTER-80 SECONDS.P3 PRESSURE SENSOR FOUND TO BE VENTING CONTINUOUSLY.

P3 SENSOR WAS REPLACED.

8-8-88 1A D/G TRIPPED AFTER-80 SECONDS.P3 PRES 8URE SENSOR WAS FOUND TO BE VENTING CONTINUOUSLY.P3 WAS REPLACED WITH SENSOR INSPECTED BY THE MANUFACTURER.

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ACT0VOTl28 DN PROGRESS TO ENHANCE RELOABOLOTY DATA COLLECT 00N/2VALUA700N OF:

- ENGINE AND GENERATOR PARAMETERS.

- ENGINE STARTS / STOPS /VARIOUS LOADINGS.

- VISUAL INSPECTION OF ENGINE AND GENERATOR.

- VISUAL IN8PECTION OF ASSOCIATED SYSTEMS.

- HEAT EXCHANGER PRESSURE DROP AND PERFORMANCE.

- VIBRATION MONITORING.

- AIR QUALITY.

- ENGINE FAILURES WITH RESPECT 70:

- CRAMM8 HAFT.

- ENGINE LOAD.

> INSTABILITY.

- OPERATOR ACTION.

- FAILED PARTS.

- ENGINE OIL.

- UNSCHEDULED MAINTENANCE.

- MANUFACTURER'S REVISED INSPECTION PROGRAM.

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RESULTS OF STATOOM PROGRAMS AND ACTOV07028

= STATION PROBLEM REPORTS / NUCLEAR STATION MODIFICAT10NS INITIATED.

- INCREASED PERIODIC CLEANING OF INJECTION PUMP SHAFTS.

- ESTABLISHED AIR QUAL!TV TEAM.

- ESTABLISHED D/0 RELIABILITY TEAM,

- DESTRUCTIVE /NON-DESTRUCTIVE RECEIPT INSPECTIONS AND TESTS.

- PLAN TO CLEAN AND FLUSH UNIT 1 FUEL OIL SYSTEM TAMES AND PIPING.

l - FAILED PARTS OR COMPONENTS SENT FOR l FAOLURE ANALYSIS STUDIES.

LONG TERM ACT0W07028 UNDER EVALUAT00N

- COMPUTER BASED ENGBNE MONITORING SYSTEM

- INSTALLATION OF FUEL COALESCING UNIT l

- INSTALLATION OF VG AUTO DRAINS.

l - RELIABILITY CENTERED MAINTENANCE EVALUATION t

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.b9BB9L l l O. Die 000 Generator Hist @ry

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00. Categorize Diesel Generator Valid ,

Failures  !

100. Corrective Actions and Results  ;

I OV. ReOlability Summa 7y l ir '

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. 1 A DOESEL GENERATOR OPERATONG

. HOSTORY Dets accumulatlen starting en 8/8/84 (DR0ft everhaul completten date)

! 1. Number of Engine Starts - 887 l' 2. Number of Times Diesel was Leaded - 283  !

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3. Number of Valid Successes - 144 i i 4. Number of Valid Falurte - 11 5 - Pneum'atic senser/legic board component prehleme l

3 - Fuel e5 erstem problems  ;

2 - Generek regulater problems  !

1 - idiscellaneous: Step /run valve  ;

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1B DOESEL GENERATOR OPERATMG ,

HISTORY l

Dete secumulation starties e/20/s4 (DROR everhaul completten date) l t

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l 1. Number of Engine Starts - 884 I

2. Number of Times Diesel wee Leeded - 294

8. Number of Valid Successee - 107

4. Num'oer of Ve5d Feturee - 9  !

5 - Pnemnette senser/logie board eeseenent probiome

! 2 - Fuel SE System probleme i 1 - Genereter regulater problem 1 - RNeestessese: Starting air malfunction Unknowe essee I

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2A DIE 8EL GENERATOR OPERATONG HOSTORY Data accumulatlen starting 2/18/86  :

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1. Number of Engins Starts - 887  ;

2. Number of Times Diesel was Leaded - 181

8. Number of Ve5d Seeeesses - 188 i

4. Number of Vaud Fagures - 4 C l 4 - Fuel Raek Binding l

1 - Fuelinjector Pump Problem  !.

1 - Engine Electronic Gevener Problem  !

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! Data escumulatlen starting 2/4/84

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1. Number of Engine Starts - 290

2. Number of Times Diesel was Leaded - 147  ;

8. Number of Valid Successes - 108

4. Number of Valid Failures - 4 1 - Pneumatic Sensor / Logic board component problems 1 - Fuel injector Pump Problem i 1 - Engine GovenorsProblem 1 - Miscellaneous - Unknown Covee i

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CATAWBA DOES2L GENERATOR VALOD FA0 LURES i

Total Number of Valid Fallures - 30 l{

11 - Pneumat!c senser/'egic board component l failurte 5 - Fuel og System feliurse 4 - Fuel rock binding failures 8 - Generater regulater failures i

7 - Miscellaneous failures j 1

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i PNEUMATIC SENSOR / LOGIC BOARD COMPONENTS VALID FAILURES (11)

A. Corrective Actlens - Already covered  !

1. Short Term l'

. 2. Long Term

! 3. Results I l

l 1. No further faNures on any diesel i Generator I l

2. Testing 1 A diesel generator twies a week l until 20 valid successes without a fature .

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FUEL OIL SYSTEM VALID FAOLURES (5) l A. Corrective Actlene

1. Short Term

-Increased frequency of fEter/ strainer cleanlag ,

2. Long Term ji

-Increased frequency of day tank cleaning l

- Modification to install coalescent unit  ;

l at day tank inlet

- Considering roeirculation of feel e5 -  !

tank after each fuel el additlen > l

! - Increased fuel el tank roeirculetlen thee

! - Adding 2 types of bleelde to control algae and fungue yewth ,

'- 5. Resulte

'. 1. Sediment /partleulate concentrations  !

conslatently remain low ,

2. No faEuros sinos 11/4/85 except for 3/7/88 R

failure  !

- Fibers elegged the strainer in a short period  :

ef time  :  ;

- Could not find eeurce of fibers .

-Inspecting strainer after every 1 hour1.157407e-5 days <br />2.777778e-4 hours <br />1.653439e-6 weeks <br />3.805e-7 months <br /> run '

- No further fibers have been found i

4 CATAWBA FD A PARTICULATE e .,

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f' FUEL RACK BONDONG VALOD FAOLURES (4) ,

A. Corrective Actlens l

1. Short Term i - Incrossed lubrication frequency l

! - Incrossed eleerence between fuel reek med the starting air header -

l 2. Long Term j - Measured fuel rock tonelen weekly for ,

2 meethe, then monthly for 8 additlenal meathe. Presently en a quarterly  ;

frequency, i -

8. Resulte -

l 1'. Fuel rock tertion has remained the j l

same  :

2. No fwther fellwee l

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i l l GENERATOR REGULATOR VALID FAILURES (3) l l

, l A. Corrective Action ;i

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! 1. Short Term 2  :

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- Replaced faulty diodes and SCR's  :

l -Installed heet eenettive tape en diedec

2. Long Term

-InsteBed sectag fene in generater control eebinete 4

- Modifleetles te insteN better heet sinke en the diodes .

- Inspect heet tape after every one ,

hour rum l

I B. Results r l 1. No additlenal failures unti 3/7/84  :

l fegure when seeling fan was found off '

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- Changed precedure to verify fan running

) l en every shift i  :

1

_ a w a._.. - - -.. . .- . , _ .  :. . . ___ .

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l i i i MISCELLAMEOUS VALOD FAOLURES (7) l-

i 2 - Unknown Failures il

' I

, 2 - Fuel Injector Pump Unkage Fauwes .

1 - F.loctronic Gevener Fe5me i

1 - Mechenleel Sevener Feture 1 - Step /Run Velve Feture li 1

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. CATAWBA DOE 8EL GENERATOR RELOABOLOTY 93338kk c

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.91tf.91.___Y.l'_ _YF_' _.YfIl.M=YT' =

_Bgthgly_

1A 169 11 4.5 98.5%

18 206 9 4.4 95.0%  !'

2A 142 6 4.2 95.4% i

2B 110 4 8.8 94.4% i l

VT'- Valid Tests  :  :

VF'- Valid Falleres M Reg Guide 1.108 Requirements 5VF'( 98X)

Station Geel 1 VF ( esX)  !

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k 3 CATAW3A D028EL GENERAT@R RELOAB0LOTY*

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_91amel.__.XI.e_ __H.e__If.eLt9.9.XL_!!aleMir_

1A 164 8 3.7 M.3% i

.l 18 201 4 2.0 MX l i

RA 1H 2 1.5 N.5% 'C 2B 100 3 2.8 97.2%

VT'- Velld Tests .

VF'- Velid Fe5eres j

• Without the paennets type feEwee sa 1 A,1B, i' and 28 and the feel reek binding preWome on 2A t

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